Adjustable locking shoe

ABSTRACT

A shoe for a band saw includes a block for coupling to the band saw, the block having an aperture, a locking ball disposed in the aperture, a body including a first surface for engaging a workpiece and an opposite surface having plurality of recesses, and a locking rod coupled to the block and movable between a first position and a second position. The locking ball is received in one of the plurality of recesses of the body when the locking rod is in the first position such that the body is fixed relative to the block, and the body is movable relative to the block when the locking rod is in the second position.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation-in-part of U.S. patent applicationSer. No. 12/508,824 filed on Jul. 24, 2009, which claims priority toU.S. Provisional Patent Application Ser. No. 61/083,703 filed on Jul.25, 2008, the entire contents of both of which are incorporated hereinby reference.

BACKGROUND

The present invention relates to a shoe for a saw, and, moreparticularly, to a shoe for a band saw.

Shoes for reciprocating saws typically include a flat or planar surfacefor engaging a workpiece. The planar surface is positioned normal to ablade of the reciprocating saw. The reciprocating saw is held by a userand positioned by the user with respect to the workpiece. The shoe doesnot aid in locating the tool with respect to the workpiece, but acts asa stop to limit the depth of the saw blade into the workpiece and toprevent the workpiece from engaging the saw blade at a connection of thesaw blade to the tool.

Band saw shoes, or workpiece bumpers, typically include a flat or planarsurface for engaging a workpiece. The flat surface lies normal to aportion of a saw blade located in a cut zone of the saw where theworkpiece is cut. As such, a band saw shoe guides the workpiece withrespect to the tool such that a perpendicular cut is made through theworkpiece.

SUMMARY

In one construction, the invention provides a shoe for a band saw. Theshoe includes a block for coupling to the band saw, the block having anaperture, a locking ball disposed in the aperture, a body including afirst surface for engaging a workpiece and an opposite surface havingplurality of recesses, and a locking rod coupled to the block andmovable between a first position and a second position. The locking ballis received in one of the plurality of recesses of the body when thelocking rod is in the first position such that the body is fixedrelative to the block, and the body is movable relative to the blockwhen the locking rod is in the second position.

In another construction the invention provides a band saw. The band sawincludes a housing supporting a motor operable to drive a continuousband saw blade to cut a workpiece, the housing having a first portionand a second portion, and a cavity between the first portion and thesecond portion for receiving the continuous band saw blade andaccommodating a workpiece during a cutting operation. The band saw alsoincludes a shoe assembly coupled adjacent the cavity to the firstportion of the housing. The shoe assembly includes a block coupled tothe band saw housing, the block including an aperture, the shoe assemblyalso including a locking ball disposed in the aperture, and a body. Thebody has a first surface for engaging a workpiece, an opposite surfacehaving a plurality of recesses, and a recess through which the band sawblade passes. The shoe assembly also includes a locking rod coupled tothe block and movable between a first position and a second position.The locking ball is received in one of the plurality of recesses of thebody when the locking rod is in the first position such that the body isfixed relative to the block, and the body is movable relative to theblock when the locking rod is in the second position.

In yet another construction, the invention provides a shoe for a bandsaw. The shoe includes a block for coupling to the band saw, the blockincluding first and second recesses, a body movable relative to theblock and including a surface for engaging a workpiece, and a leverpivotable between a first position and a second position and including abutton portion and a locking portion. The locking portion is received inone of the recesses when the lever is in the first position such thatthe body is substantially fixed relative to the block. The body ismovable relative to the block when the lever is in the second position.

In yet another construction, the invention provides a band saw. The bandsaw includes a housing having a first portion and a second portion andsupporting a motor operable to drive a continuous band saw blade to cuta workpiece, a cavity between the first portion and the second portionfor receiving the continuous band saw blade and accommodating aworkpiece during a cutting operation, and a shoe assembly coupledadjacent the cavity to the first portion of the housing. The shoeassembly includes a block for coupling to the band saw, the blockincluding first and second recesses, a body movable relative to theblock and including a surface for engaging a workpiece, and a leverpivotable between a first position and a second position and including abutton portion and a locking portion. The locking portion is received inone of the recesses when the lever is in the first position such thatthe body is substantially fixed relative to the block. The body ismovable relative to the block when the lever is in the second position.

Other aspects of the invention will become apparent by consideration ofthe detailed description and accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a front view of a band saw including an adjustable lockingshoe system according to one construction of the invention.

FIG. 2 is a bottom perspective view of the band saw of FIG. 1.

FIG. 3 is a close-up perspective view of a portion of the band saw ofFIG. 1.

FIG. 4 is an exploded perspective view of the adjustable locking shoesystem of FIG. 1.

FIG. 5 is a perspective view of the adjustable locking shoe system ofFIG. 4.

FIG. 6 is a cross section of the adjustable locking shoe system takenalong line 6-6 of FIG. 3.

FIG. 7 is a cross section of the adjustable locking shoe system takenalong line 7-7 of FIG. 5, the adjustable locking shoe system being in alocked position.

FIG. 8 is a cross section of the adjustable locking shoe system takingalong line 7-7 of FIG. 5, the adjustable locking shoe system being in anunlocked position.

FIG. 9 is a perspective view of a portion of a band saw including anadjustable locking shoe system according to another construction of theinvention.

FIG. 10 is an exploded view of the adjustable locking shoe system ofFIG. 9.

FIG. 11 is a rear perspective view of the adjustable locking shoe systemof FIG. 9 in a locked position.

FIG. 12 is a rear perspective view of the adjustable locking shoe systemof FIG. 9 in an unlocked position.

FIG. 13 is a front perspective view of the adjustable locking shoesystem of FIG. 9.

FIG. 14 is a rear view of a portion of the adjustable locking shoesystem of FIG. 11.

FIG. 15 is an isolated view of the lever and connector block shown inFIG. 14.

Before any constructions of the invention are explained in detail, it isto be understood that the invention is not limited in its application tothe details of construction and the arrangement of components set forthin the following description or illustrated in the following drawings.The invention is capable of other constructions and of being practicedor of being carried out in various ways.

DETAILED DESCRIPTION

FIGS. 1-8 illustrate a band saw 10 and an auto-locking, tool-lessadjustable shoe system 12 embodying some aspects of the invention. An ACversion of the band saw 10 having an electrical connection cord 12 isillustrated; however, in further constructions, DC versions of the bandsaw 10 including a rechargeable, removable battery pack are possible.

The band saw 10 includes a housing or frame 14 supporting a motor 18 anda gear box 22. The motor 18 is drivingly connected to a drive mechanism(not shown) at least partially housed within the gear box 22. The motor18 and the drive mechanism are operable to drive a continuous band sawblade 26 to cut a workpiece. As described herein, the band saw 10includes a front 30 and a rear 34. The front 30 is defined as the sidebeing proximate the portion of the band saw blade 26 that cuts theworkpiece and the rear 34 is defined as the side proximate the portionof the band saw blade 26 that does not cut the workpiece. The rear 34 isotherwise described as being opposite the front 30.

The housing 14 includes a main handle 38 supporting a switch assembly 42to provide power to the band saw 10. The switch assembly 42 is operableto control operation of the motor 18. The band saw 10 also includes anauxiliary handle 46 for a user's other hand spaced from the main handle38. Generally, the handles 38, 46 are shaped and arranged for two-handedoperation of the band saw 10 as the workpiece is cut. In the illustratedconstruction, each handle 38, 46 has an ergonomic design to providecomfortable gripping and controlled operation of the band saw. Theergonomic design of each handle and of the combination of the handlesmay include the orientation or angle of handle(s). The ergonomic designmay also include the use of material, such as an elastomeric material,on the handle(s) to, one or more of, provide an improved grip surface,isolate vibration and impacts from the operator, prevent heat build-upand/or transfer to the operator, etc.

The housing 14 defines a first portion 50 and a second portion 54. Thefirst portion 50 and the second portion 54 are spaced apart from oneanother and define a U-shaped cavity 66 defining a cut zone 58therebetween. A blade guard 62 (FIG. 2) is positioned at the rear 34 ofthe band saw 10 and extends between the first and second portions 50, 54within the cut zone 58. The blade guard 62 provides a recessed area tohouse the band saw blade 26.

As shown in FIG. 2, the drive mechanism generally includes a drive wheelpulley 70 and a driven wheel pulley 74. The drive wheel 70 rotates abouta drive wheel axis 78 defined by a drive wheel axle 80 and is drivinglyconnected to the motor 18 via a drive train (not shown). The drivenwheel 74 rotates about a driven wheel axis 82 defined by a driven wheelaxle 84 and is rotatably supported by the housing 14. The drive wheel 70is positioned in the first portion 50 of the housing 14, and the drivenwheel 74 is positioned in the second portion 54 of the housing 14. Awheel tire 86 is coupled to each of the peripheries of the drive wheel70 and the driven wheel 74. Each wheel tire 86 is a circular-shaped ringformed of a soft and/or flexible elastomeric material that is able tolock or adhere to the respective wheel 70, 74. The band saw blade 26extends around the drive wheel 70 and the driven wheel 74 and grips theblade tires 86 and, as a result, motion from the drive wheel 70 istransmitted to the band saw blade 26 via the blade tires 86. The bandsaw 10 also includes a blade tensioning mechanism 90 (FIG. 1) toadjustably provide appropriate tension on the band saw blade 26.

A first guide roller set 94 and a second guide roller set 98 aredisposed on each side of the cavity 66 and engage opposing sides of thesaw blade 26. The first and second guide roller sets 94, 98 support theband saw blade 26 as the blade 26 enters and exits the cut zone 58.Although the second guide roller set 98 is not entirely visible in FIG.2, it is substantially a mirror of the first guide roller set 94.

Referring to FIGS. 3-8, the adjustable shoe system 12 includes a shoe100 for positioning against the workpiece, a connector block 104 forcoupling the shoe 100 to the housing 14, and a detent mechanism 108(FIGS. 6-8) for locking the shoe 100 in select positions relative to theconnector block 104. The shoe 100 includes a distal end 110 having adistance from the connector block 104 that varies depending on theposition of the shoe 100. The shoe 100 is coupled to the housing 14 byway of the connector block 104 and the detent mechanism 108.

With reference to FIGS. 4 and 5, the connector block 104 is a generallyT-shaped member coupled to the housing 14 by fasteners 112 (FIG. 6). Theconnector block 104 is coupled to the first portion 50 of the housing 14adjacent the drive wheel 70 and is positioned in or adjacent the cavity66 at an end of the cut zone 58. The connector block 104 includesfastener apertures 116 through which the fasteners 112 are disposed tocouple the connector block 104 to the housing 14. In the illustratedconstruction, two fastener apertures 116 and two screws 112 areemployed. In other constructions, fewer or more fasteners and fastenerapertures may be employed to couple the connector block 104 to thehousing 14, or the connector block 104 may be integrally formed as onepiece with the housing 14. In other constructions, the fasteners 112 maybe other suitable types of fasteners.

The connector block 104 includes a main body portion 120 and first andsecond extending portions or flanges 124, 128 generally forming aT-shaped cross-section, as shown in FIGS. 4-5. In the illustratedconstruction, the main body portion 120 is positioned adjacent thehousing 14 and engages the housing 14 when the connector block 104 isfastened to the housing 14. The first and second extending portions 124,128 mate with the shoe 100, as described below. The main body portion120 of the connector block 104 also includes recesses or apertures 132for receiving locking balls 136, and rod support tabs 140 havingapertures 144 a, 144 b for receiving a locking rod 148 to lock the shoe100 in place relative to the connector block 104. In the illustratedconstruction, two locking balls 136 and two apertures 132 are employed.In other constructions, one, three or more locking balls 136 may beemployed, and accordingly, one, three or more apertures 132 may beemployed to receive the locking balls 136.

The detent mechanism 108 includes the locking balls 136, the locking rod148, a biasing member 152, such as a leaf spring, a compression spring156 and a button 160. The biasing member 152 includes a first M-shapedcurved portion 152 a positioned between a second portion 152 b and athird portion 152 c (FIG. 4). The locking rod 148 includes a smalldiameter portion 164, a large diameter portion 168 and a tapered portion166 transitioning smoothly between the small diameter portion 164 andthe large diameter portion 168. The small diameter portion 164 issupported in the aperture 144 a. The large diameter portion is supportedin the aperture 144 b, which accordingly has a larger diameter than theaperture 144 a. The button 160 is coupled to a distal end of the smalldiameter portion 164, and the compression spring 156 is coupled to thesmall diameter portion 164 of the locking rod 148 between the button 160and the rod support tab 140.

The compression spring 156 biases the locking rod 148 to a lockedposition (FIGS. 5 and 7) in which the shoe 100 is fixed relative to theconnector block 104. In the locked position, the large diameter portion168 of the locking rod 148 engages the first portion 152 a of thebiasing member 152 and applies a force to the biasing member 152 towardthe connector block 104, against a spring force of the biasing member152, to trap the locking balls 136 between the connector block 104 andthe first and second portions 152 b, 152 c of the biasing member 152.The button 160 and the locking rod 148 are extended away from theconnector block 104 in the locked position. The button 160 isdepressible against the biasing force of the compression spring 156 toan unlocked position (FIG. 8) in which the shoe 100 is movable relativeto the connector block 104. In the unlocked position, the small diameterportion 164 of the locking rod 148 is adjacent the biasing member 152,providing a clearance that releases the biasing member 152 and thus thelocking balls 136. The biasing member 152 is released to its biasedposition away from the locking balls 136 such that the locking balls 136are not trapped between the connector block 104 and the first and secondportions 152 b, 152 c of the biasing member 152. The button 160 andlocking rod 148 are positioned closer to the connector block 104 in theunlocked position.

The shoe 100 includes a generally C-shaped body member 172 and aworkpiece-engaging member 176. The body member 172 wraps around andslideably engages the first and second extending portions 124, 128 ofthe connector block 104. An axis A of the adjustable shoe system 12 isparallel to the direction the shoe 100 slides relative to the connectorblock 104 and is defined by a longitudinal axis of the connector block104. In the illustrated construction, the apertures 132 and the fastenerapertures 116 are centered on the axis A. The workpiece-engaging member176 generally extends along the axis A below the cut zone 58 and awayfrom the housing 14 of the band saw 10 (FIG. 3). The shoe 100, and inparticular the workpiece-engaging member 176, engages a workpiece (notshown) in order to secure the workpiece relative to the band saw blade26 within the cut zone 58 during a cutting operation. Theworkpiece-engaging member 176 includes a groove or slot 180 in which theband saw blade 26 is positioned, as shown in FIGS. 1-3. The direction ofmovement of the band saw blade 26 through the slot 180 is generallyperpendicular to the axis A, and a plane of the band saw blade 26extending through the slot 180 is generally parallel to the axis A.

The shoe 100 also includes apertures 184 a-184 f for receiving thelocking balls 136 in order to lock the shoe 100 in position relative tothe housing 14, i.e., the locked position (FIG. 7). The locking balls136 are urged toward the shoe 100 by the biasing member 152 when thelocking rod is in the locked position, as described above. In the lockedposition, the locking balls 136 are seated in the apertures 132 of theconnector block 104 such that a portion of the locking balls 136 crossthe plane of an exterior surface 188 of the connector block 104 adjacentthe shoe 100. Thus, said portion of the locking balls 136 protrudes fromthe exterior surface 188 toward the shoe 100. Respective apertures 184a-184 f in the shoe 100 receive said portion of the locking balls 136,which are locked in place by the force of the locking rod 148, tofixedly hold the shoe 100 in a position corresponding to the respectiveapertures 184 a-184 f. In the illustrated construction, the shoe 100includes six apertures 184 a-184 f and is adjustable between first,second, third and fourth positions.

The first position is an extended position (shown in FIG. 7) in whichthe shoe 100 extends away from the housing 14 for accommodating largerworkpieces. In the first position, the locking balls 136 are received bythe apertures 184 a and 184 c. The second, third and fourth positionsare recessed positions (i.e., toward the housing 14) for accommodatingsmaller workpieces or cutting flush against a surface, such as a ceilingor wall. The third position is more recessed than the second position,and the fourth position is more recessed than the third position. In thesecond position, the locking balls 136 are received by the apertures 184b and 184 d. In the third position, the locking balls 136 are receivedby the apertures 184 c and 184 e. In the fourth position, the lockingballs 136 are received by the apertures 184 d and 184 f. In the fourthposition, or fully recessed position, the end of the shoe 110 isadjacent or near a bottom edge (i.e., the cutting edge) of the band sawblade 26.

Non-engaged positions, or intermediate positions, include positions inbetween the first, second, third and fourth positions. In thenon-engaged position shown in FIG. 8, the locking balls 136 are notreceived by the apertures 184 a-184 f. The non-engaged position may alsoinclude a position in which the shoe 100 is removed from the connectorblock 104. In other constructions, fewer or more apertures 184 a-184 fmay be employed such that the shoe 100 is adjustable between fewer ormore positions for positioning and securing the band saw 10 with respectto a variety of workpieces of varying sizes and shapes.

In operation, the locking rod 148 is biased to an extended, or locked,position by the compression spring 156 in which the large diameterportion 168 exerts a force on the biasing member 152 toward theconnector block 104. The force pushes the locking balls 136 toward theshoe 100 such that when the locking balls 136 are received by therespective apertures 184 a-184 f in the shoe 100, the locking balls 136are trapped between the biasing member 152 and the shoe 100. In thelocked position, the shoe 100 is inhibited from movement relative to theconnector block 104 or the housing 14.

In order to adjust the position of the shoe 100, a user applies a forceto the button 160 in a direction perpendicular to the axis A and towardthe connector block 104, as shown by the arrow B in FIG. 3. The forcecauses the locking rod 148 to move from the extended position, in whichthe large diameter portion 168 is adjacent the biasing member 152, to anunlocked, or recessed, position, in which the small diameter portion 164is adjacent the biasing member 152. In the unlocked position, the smalldiameter portion 164 provides a clearance that alleviates or removes theforce on the biasing member 152, which allows the locking balls 136 tobe released from the respective apertures 184 a-184 f such that the shoe100 is movable relative to the connector block 104. The locking balls136 slide relative to an inner surface 192 of the shoe 100, which facesthe exterior surface 188 of the connector block 104, as shown in FIG. 8.The user applies a moving force while sliding the shoe 100 in adirection parallel to the axis A and releases the button 160 when adesired position is reached. The tapered portion 166 allows the lockingrod 148 to transition smoothly such that the large diameter portion 168can re-engage the biasing member 152. Upon release of the button 160,the user must find a position in which the locking balls 136 arereceived by the respective apertures 184 a-184 f to lock the shoe 100 inplace. The button 160 and locking rod 148 are biased to the lockedposition by the compression spring 156 such that, upon release of thebutton 160, the button 160 moves to the extended, or locked, position.Thus, the shoe 100 is locked in place when the button 160 is released.

No tools or removal of fasteners are required to adjust or remove theshoe 100, and the button 160 is deliberately depressed in order to movethe shoe 100. However, if the shoe is unintentionally overloaded, thebiasing member 152 is flexible and can bend to prevent damage to theshoe 100 and the detent mechanism 108.

In other constructions, the locking rod may be rotatable for one-handedoperation and include a non-circular cross section, such as asemi-circular cross section, such that the rod engages the biasingmember 152 in one angular position and releases the biasing member 152in another angular position. In yet other constructions, the locking rodmay be a ramped pin and a second locking ball may replace the biasingmember 152 adjacent the first locking ball such that when one end of theramp is adjacent the locking balls, a space is provided such that theshoe 100 is movable with respect to the connector block 104, and when anopposite end of the ramp is adjacent the locking balls, the lockingballs are trapped to lock the shoe 100 with respect to the connectorblock 104. In this construction, an optional biasing member and detentball may be provided, independent from the functional locking ballsdescribed above, to be positioned in a second of the apertures 184 a-184f to stabilize the shoe 100 and provide a detent-like feel to the user.

FIGS. 9-13 illustrate another construction of a toolless adjustable shoesystem 12 a. The shoe system 12 a has a shoe 100 a for positioningagainst the workpiece, a connector block 104 a for coupling the shoe 100a to the housing 14, and a locking mechanism 108 a for locking the shoe100 a in select positions relative to the connector block 104 a. Theshoe 100 a includes a distal end 110 a having a distance from theconnector block 104 a that varies depending on the position of the shoe100 a. The shoe 100 a is coupled to the housing 14 by way of theconnector block 104 a and the locking mechanism 108 a.

The connector block 104 a is a generally T-shaped member coupled to thehousing 14 by fasteners 112 a, as described above with respect to theconnector block 104. The connector block 104 a includes a main bodyportion 120 a and first and second extending portions or flanges 124 a,128 a generally forming a T-shape, as shown in FIG. 10. In theillustrated construction, the main body portion 120 a is positionedadjacent the housing 14 and engages the housing 14 when the connectorblock 104 a is fastened to the housing 14. An opposite side 240 of theconnector block 104 a includes a biasing member 244, such as a leafspring, to provide a force on the side of the shoe 100 a facing theopposite side 240 of the connector block 104 a, as is best illustratedin FIG. 13. The leaf spring 244 provides pressure on the back of theshoe 100 a to inhibit the shoe 100 a from wobbling transverse to theaxis C with respect to the connector block 104 a. The leaf spring 244includes apertures at each end through which the fasteners 112 a pass tosecure the leaf spring 244 to the connector block 104 a.

The first and second extending portions 124 a, 128 a of the connectorblock 104 a mate with the shoe 100 a, as described above with respect tothe first construction of the shoe system 12. The main body portion 120a of the connector block 104 a also includes recesses 200 a-200 c forreceiving a locking portion 204 of a lever 208 to lock the shoe 100 a inplace relative to the connector block 104 a. In the illustratedconstruction, three recesses 200 a-200 c are employed, resulting inthree positions in which the shoe 100 a can be locked. In otherconstructions, one, two, four or more recesses may be employed to allowfor one, two four or more positions in which the shoe 100 a can belocked.

The first position is an extended position (shown in FIG. 9) in whichthe shoe 100 a extends away from the housing 14 for accommodating largerworkpieces. In the first position, the locking portion 204 of the lever208 engages the lower recess 200 a. The second and third positions arerecessed positions (i.e., toward the housing 14) for accommodatingsmaller workpieces or cutting flush against a surface, such as a ceilingor wall. The third position is more recessed than the second position.In the second position, the locking portion 204 of the lever 208 engagesthe middle recess 200 b. In the third position (shown in phantom in FIG.9), the locking portion 204 of the lever 208 engages the upper recess200 c. In the third position, or fully recessed position, the end of theshoe 110 a is adjacent or near a bottom edge (i.e., the cutting edge) ofthe band saw blade 26.

The locking mechanism 108 a includes the lever 208, the recesses 200a-200 c, a pivot pin 212, a biasing member 216, such as a compressionspring, and a lever housing 220. The lever 208 includes the lockingportion 204, a pivot aperture 224, and a button 228. The biasing member216 is received in the button 228 at one end and coupled to a pin 232within the lever housing 220 at another end and provides a force thatbiases the button 228 to a locked position (FIG. 11) positioned awayfrom the connector block 104 a. In the locked position, the button 228extends out of an opening 236 in the lever housing 220. The lever 208 ispivoted about the pivot pin 212 such that the locking portion 204 isdisposed in one of the recesses 200 a-200 c to inhibit movement of theshoe 100 a relative to the connector block 104 a. In an unlockedposition (FIG. 12), the button 228 is closer to the housing than in thelocked position and is parallel to and nearly flush with the opening 236in the lever housing 220. The lever 208 is pivoted about the pin 212such that the locking portion 204 slides along the main body portion 120a of the connector block 104 a between recesses 200 a-200 c. In theunlocked position, the shoe 100 a and locking mechanism 108 a aremoveable relative to the connector block 104 a.

The pivot pin 212 defines a pivot axis D that is non-parallel to, andmore specifically, perpendicular to the longitudinal axis C of theconnector block 104 a. The lever 208 defines a longitudinal axis E(FIGS. 14-15) through a longitudinal portion 214 of the lever 208. Thepivot axis D passes through longitudinal portion 214 and isperpendicular to and intersects the longitudinal axis E.

In the locked position, shown in FIG. 15, an axis G is defined betweenthe pivot point of the pivot pin 212 and the ramped surface 206 of thelocking portion 204, preferably to an approximate center point on theramped surface 206, as illustrated. The axis G is perpendicular to thepivot axis D.

With reference to FIGS. 14-15, the recesses 200 a-200 c are generallyparallelepiped in shape having at least one ramped surface 202 a-202 c,i.e., a surface that forms an angle F greater than 90 degrees withrespect to the axis G when the locking portion 204 is received in one ofthe recesses 200 a-200 c. The ramped surface 202 a-202 c engages aramped surface 206 on the locking portion 204 of the lever 208.

The ramped surface 206 of the locking portion 204 defines an axis H thatforms the same angle F, greater than 90 degrees, with respect to theaxis G. The locking portion 204 of the lever 208 and the recesses 200a-200 c are ramped to allow for overload of the shoe assembly 12 a if,for example, the band saw is dropped. When overloaded, the opposingramped surfaces 206, 202 a-202 c on the locking portion 204 andrespective recess 200 a-200 c allow the locking mechanism 108 a torelease, such that the locking portion 204 is released from therespective recess 200 a-200 c and the shoe 100 a slides upward relativeto the connector block 104 a to avoid damage.

In the illustrated construction, the lever housing 220 is formed as onepiece with the shoe 100 a, such as by investment casting. In otherconstructions, the lever housing 220 can be formed separately from theshoe 100 a and may be made of a plastic.

The shoe 100 a includes a generally C-shaped body member 172 a and aworkpiece-engaging member 176 a, as described above with respect to theshoe 100. The body member 172 a wraps around and slideably engages thefirst and second extending portions 124 a, 128 a of the connector block104 a. The axis C of the adjustable shoe system 12 a is parallel to thedirection the shoe 100 a slides relative to the connector block 104 aand is defined by the longitudinal axis of the connector block 104 a. Inthe illustrated construction, fastener apertures 116 a are centered onthe axis C, and the recesses extend into the main body portion 120 a ina direction transverse to the axis C.

The workpiece-engaging member 176 a generally extends along the axis Cbelow the cut zone 58 and away from the housing 14 of the band saw 10(FIG. 9). The shoe 100 a, and in particular the workpiece-engagingmember 176 a, engages a workpiece (not shown) in order to secure theworkpiece relative to the band saw blade 26 within the cut zone 58during a cutting operation. The workpiece-engaging member 176 a includesa groove or slot 180 a in which the band saw blade 26 is positioned. Thedirection of movement of the band saw blade 26 through the slot 180 a isgenerally perpendicular to the axis C, and a plane of the band saw blade26 extending through the slot 180 a is generally parallel to the axis C.

Non-engaged positions, or intermediate positions, include positions inbetween the first, second and third positions. In the non-engagedposition shown in FIG. 12, the locking portion 204 of the lever 208engages a side of the main body portion 120 a. The non-engaged positionmay also include a position in which the shoe 100 a is removed from theconnector block 104 a. In other constructions, fewer or more recesses200 a-200 c may be employed such that the shoe 100 a is adjustablebetween fewer or more positions for positioning and securing the bandsaw 10 with respect to a variety of workpieces of varying sizes andshapes.

In operation, the button 228 is biased to an extended, or locked,position by the compression spring 216. The force pushes the lockingportion 204 toward the recesses 200 a-200 c in the connector block 104 asuch that the locking portion 204 is biased into an adjacent recess 200a-200 c. In the locked position, the shoe 100 is inhibited from movementrelative to the connector block 104 or the housing 14.

In order to adjust the position of the shoe 100 a, a user maysingle-handedly apply a force to the button 228 in a directionperpendicular to the axis C and toward the connector block 104 and thenslide the shoe 100 a and locking mechanism 108 a up or down between theextended and recessed positions. The force causes the locking portion204 to move from a locked position, in which the locking portion 204abuts one of the recesses 200 a-200 c, to an unlocked position, in whichthe locking portion 204 disengages the recess 200 a-200 c and isslidable relative to the connector block 104 a in a direction parallelto the axis C. The user applies a moving force while sliding the shoe100 a in a direction parallel to the axis C and releases the button 228when an approximate desired position is reached. The button 228 may alsobe released at any time and the shoe 100 a will remain movable until thelocking portion 204 snaps into an adjacent recess 200 a-200 c. Uponrelease of the button 228, the user must find a position in which thelocking portion 204 is received by one of the respective recesses 200a-200 c to lock the shoe 100 a in place. The button 228 locking portion204 are biased to the locked position by the compression spring 216 suchthat, upon release of the button 228 and the locking portion 204engaging a recess 200 a-200 c, the button 228 moves to the lockedposition. Thus, the shoe 100 a is locked in place when the button 228 isreleased and the locking portion 204 is positioned in a recess 200 a-200c.

No tools or removal of fasteners are required to adjust or remove theshoe 100 a, the button 228 is deliberately depressed in order to movethe shoe 100 a, and the shoe 100 a can be adjusted with one-handedoperation. However, if the shoe is unintentionally overloaded, thelocking portion 204 can move to the unlocked position by affectingmovement between the ramped surfaces to prevent damage to the shoe 100 aand the locking mechanism 108 a.

Although particular constructions embodying independent aspects of theinvention have been shown and described, other alternative constructionswill become apparent to those skilled in the art and are within theintended scope of the independent aspects of the invention.

Thus, the invention provides, among other things, an adjustable lockingshoe for a band saw. Various features and advantages of the inventionare set forth in the following claims.

1. A shoe for a band saw, the shoe comprising: a block for coupling tothe band saw, the block including an aperture; a locking ball disposedin the aperture; a body including a first surface for engaging aworkpiece and an opposite surface having a plurality of recesses; and alocking rod coupled to the block and movable between a first positionand a second position, wherein the locking ball is received in one ofthe plurality of recesses of the body when the locking rod is in thefirst position such that the body is substantially fixed relative to theblock, and wherein the body is movable relative to the block when thelocking rod is in the second position.
 2. The shoe of claim 1, andfurther comprising a biasing member disposed between the locking rod andthe block, wherein the locking rod applies a force to the biasing memberto hold the locking ball in one of the plurality of recesses when thelocking rod is in the first position.
 3. The shoe of claim 2, whereinthe locking rod includes a first diameter portion and a second diameterportion that has a smaller diameter than the first diameter portion,wherein the first diameter portion engages the biasing member to applythe force to the biasing member when the locking rod is in the firstposition.
 4. The shoe of claim 3, wherein the second diameter portion ispositioned proximate the biasing member when the locking rod is in thesecond position to release the force on the biasing member and releasethe locking ball from engagement in the one of the recesses in the body.5. The shoe of claim 2, wherein the biasing member includes a leafspring having a first portion for engaging the locking rod and a secondportion for engaging the locking ball.
 6. The shoe of claim 5, whereinthe locking ball is a first locking ball and the aperture is a firstaperture, the block further including a second aperture and the shoefurther comprising a second locking ball disposed in the secondaperture, wherein the biasing member further includes a third portionfor engaging the second locking ball.
 7. The shoe of claim 6, whereinthe first portion of the biasing member is positioned between the secondportion and the third portion.
 8. The shoe of claim 1, wherein thelocking rod translates axially between the first and second positions.9. The shoe of claim 8, wherein the body is movable in an axialdirection that is substantially perpendicular to the axial translationof the locking rod.
 10. The shoe of claim 8, wherein the locking rodincludes a distal end that extends from the block a first distance inthe first position and a second distance in the second position, whereinthe first distance is greater than the second distance.
 11. The shoe ofclaim 1, further comprising a compression spring disposed about thelocking rod to bias the locking rod to the first position.
 12. A bandsaw comprising: a housing supporting a motor operable to drive acontinuous band saw blade to cut a workpiece, the housing having a firstportion and a second portion; a cavity between the first portion and thesecond portion for receiving the continuous band saw blade andaccommodating a workpiece during a cutting operation; and a shoeassembly coupled adjacent the cavity to the first portion of thehousing, the shoe assembly comprising, a block coupled to the band sawhousing, the block including an aperture; a locking ball disposed in theaperture; a body including a first surface for engaging a workpiece, anopposite surface having a plurality of recesses, and a recess throughwhich the band saw blade passes; and a locking rod coupled to the blockand movable between a first position and a second position; wherein thelocking ball is received in one of the plurality of recesses of the bodywhen the locking rod is in the first position such that the body issubstantially fixed relative to the block, and wherein the body ismovable relative to the block when the locking rod is in the secondposition.
 13. The band saw of claim 12, and further comprising a biasingmember disposed between the locking rod and the block, wherein thelocking rod applies a force to the biasing member to hold the lockingball in one of the plurality of recesses when the locking rod is in thefirst position.
 14. The band saw of claim 13, wherein the locking rodincludes a first diameter portion and a second diameter portion that hasa smaller diameter than the first diameter portion, wherein the firstdiameter portion engages the biasing member to apply the force to thebiasing member when the locking rod is in the first position.
 15. Theband saw of claim 14, wherein the second diameter portion is positionedproximate the biasing member when the locking rod is in the secondposition to release the force on the biasing member and release thelocking ball from engagement in the one of the recesses in the body. 16.The band saw of claim 13, wherein the biasing member includes a leafspring having a first portion for engaging the locking rod and a secondportion for engaging the locking ball.
 17. The band saw of claim 16,wherein the locking ball is a first locking ball and the aperture is afirst aperture, the block further including a second aperture and theshoe further comprising a second locking ball disposed in the secondaperture, wherein the biasing member further includes a third portionfor engaging the second locking ball.
 18. The band saw of claim 17,wherein the first portion of the biasing member is positioned betweenthe second portion and the third portion.
 19. The band saw of claim 12,wherein the locking rod translates axially between the first and secondpositions
 20. The band saw of claim 19, wherein the body is movable inan axial direction that is substantially perpendicular to the axialtranslation of the locking rod.
 21. The band saw of claim 19, whereinthe locking rod includes a distal end that extends from the block afirst distance in the first position and a second distance in the secondposition, wherein the first distance is greater than the seconddistance.
 22. The band saw of claim 12, further comprising a compressionspring disposed about the locking rod to bias the locking rod to thefirst position.
 23. The band saw of claim 12, wherein the portion of theband saw blade located in the cavity defines a longitudinal axis, andwherein the body is movable in an axial direction substantiallyperpendicular to the longitudinal axis of the blade.
 24. A shoe for aband saw, the shoe comprising: a block for coupling to the band saw, theblock including first and second recesses; a body movable relative tothe block and including a surface for engaging a workpiece; and a leverpivotable between a first position and a second position and including abutton portion and a locking portion, wherein the locking portion isreceived in one of the recesses when the lever is in the first positionsuch that the body is substantially fixed relative to the block, andwherein the body is movable relative to the block when the lever is inthe second position.
 25. The shoe of claim 24, wherein the buttonportion is depressible to enact pivotal movement of the lever from thefirst position to the second position.
 26. The shoe of claim 24, whereinthe body is movable in a direction with respect to the block, andwherein the first and second recesses and the locking portion includeramped surfaces to allow the body to move from the first position to thesecond position when an overloaded force is applied to the body in thedirection of movement of the body.
 27. The shoe of claim 26, wherein thelever includes a pivot axis and an axis intersecting the pivot axis thatextends between the pivot axis and a point on the ramped surface of thelocking portion, wherein the ramped surface of the locking portion liesat an angle with respect to the axis, wherein the angle is greater than90 degrees.
 28. The shoe of claim 24, further comprising a biasingmember coupled to the lever to bias the lever to the first position. 29.The shoe of claim 24, wherein the body includes a lever housing in whichthe lever is disposed, the lever housing including an aperture throughwhich the button portion is accessible to a user.
 30. The shoe of claim24, further comprising a biasing member disposed between the block andthe body to apply a pressure between the block and the body.
 31. Theshoe of claim 30, wherein the biasing member is a leaf spring coupled tothe block.
 32. The shoe of claim 24, wherein the lever is pivotable in aplane that is substantially parallel to the surface of the body.
 33. Aband saw comprising: a housing supporting a motor operable to drive acontinuous band saw blade to cut a workpiece, the housing having a firstportion and a second portion; a cavity between the first portion and thesecond portion for receiving the continuous band saw blade andaccommodating a workpiece during a cutting operation; and a shoeassembly coupled adjacent the cavity to the first portion of thehousing, the shoe assembly comprising, a block for coupling to the bandsaw, the block including first and second recesses; a body movablerelative to the block and including a surface for engaging a workpiece;and a lever pivotable between a first position and a second position andincluding a button portion and a locking portion, wherein the lockingportion is received in one of the recesses when the lever is in thefirst position such that the body is substantially fixed relative to theblock, and wherein the body is movable relative to the block when thelever is in the second position.
 34. The band saw of claim 33, whereinthe button portion is depressible to enact pivotal movement of the leverfrom the first position to the second position.
 35. The band saw ofclaim 33, wherein the body is movable in a direction with respect to theblock, and wherein the first and second recesses and the locking portioninclude ramped surfaces to allow the body to move from the firstposition to the second position when an overloaded force is applied tothe body in the direction of movement of the body.
 36. The shoe of claim35, wherein the lever includes a pivot axis and an axis intersecting thepivot axis that extends between the pivot axis and a point on the rampedsurface of the locking portion, wherein the ramped surface of thelocking portion lies at an angle with respect to the axis, wherein theangle is greater than 90 degrees.
 37. The band saw of claim 33, furthercomprising a biasing member coupled to the lever to bias the lever tothe first position.
 38. The band saw of claim 33, wherein the bodyincludes a lever housing in which the lever is disposed, the leverhousing including an aperture through which the button portion isaccessible to a user.
 39. The band saw of claim 33, further comprising abiasing member disposed between the block and the body to apply apressure between the block and the body.
 40. The band saw of claim 39,wherein the biasing member is a leaf spring coupled to the block. 41.The band saw of claim 33, wherein the lever is pivotable in a plane thatis substantially parallel to the surface of the body.
 42. The band sawof claim 33, wherein the portion of the band saw blade located in thecavity defines a longitudinal axis, and wherein the lever is pivotablein a plane that is substantially perpendicular to the longitudinal axis.43. The band saw of claim 33, wherein the portion of the band saw bladelocated in the cavity defines a longitudinal axis, and wherein the leveris pivotable about a pivot axis that is substantially parallel to thelongitudinal axis.